3d-food product forming apparatus and process

ABSTRACT

The present invention is related to a food forming apparatus to produce patties with a form member which comprises moulds in which the patties are formed, whereas the form member is located adjacent to a pressure member and is at least partially made from a porous material.

CLAIM OF PRIORITY

This application is a divisional application of U.S. Ser. No. 13/641,249filed Oct. 15, 2012, which is a national phase filing under 35 USC §371from PCT Application serial number PCT/EP2011/002075 filed on Apr. 26,2011, and claims priority therefrom. This application further claimspriority from EP 10004318.1 filed on Apr. 23, 2010, EP 10008660.2 filedon Aug. 19, 2010, EP 10009039.8 filed on Aug. 31, 2010, EP 10010255.7filed on Sep. 23, 2010 and EP 10013264.6 filed on Oct. 4, 2010 all areincorporated herein by reference.

TECHNICAL FIELD

The present invention is related to a food forming apparatus to producepatties with a form member which comprises moulds in which the pattiesare formed, whereas the form member is located adjacent to a pressuremember and is at least partially made from a porous material.

BACKGROUND OF THE INVENTION

Food product forming apparatus are known from the state of the art andare used to shape food products, for example meat, fish, spinach orcheese. This apparatus normally comprises either a form plate which ismoving reciprocally from a fill-position to a discharge-position. In adifferent embodiment, the machine comprises a rotating form drum inwhich the products are formed and subsequently discharged. In manycases, the mould, in which the food products are formed into patties isat least partially made of a porous material. This porous material hasthe advantage, that the mould can be vented during filling and that amedium, for example air, can be discharged through the porous materialin order to remove the formed patties from the mould. In most cases,these patties are shaped disc-like; i.e. 2-D-shaped. However, there isan increasing demand to provide patties with a more complex structure,3D-structure.

SUMMARY OF THE INVENTION

It was therefore the objective of the present invention to provide afood product forming apparatus and a process in which more complexpatties can be produced.

The problem is solved with a food forming apparatus to produce pattieswith a form member which comprises a mould in which the patties areformed, whereas the form member is located adjacent to a pressure memberand is at least partially made from a porous material and the pressureelement is 3D-shaped.

The present invention relates to a food product forming apparatus. Thisapparatus comprises a form member in which the food product, for exampleminced meat, is brought into the desired shape. This form member can beeither a form plate or a form drum. In case the form member is a formplate, this plate moves reciprocally from a fill-position to adischarge-position. In case the form member is a drum, this drum rotatescontinuously. In one angular position of the drum, moulds in the drumare filled with the food and in another angular position, the formedpatties are discharged.

According to the present invention the form plate is located adjacent toa pressure member and preferably between a de-aeration member,preferably a plate or a drum and the pressure member. The de-aerationmember allows the venting of the mould, while it is being filled. Thede-aeration member can also be used to connect the mould to a pressuremedium source, for example to eject the patties from the mould.

The person skilled in the art understands that the venting-function andthe connection to a pressure medium source can also be integrated intothe form member. The de-aeration member is normally located on theopposite side of the form member relative to side, from which it isfilled, while the pressure member and the means to fill the mould arelocated on the same side. The pressure member is preferably used toavoid leakages during the filling of the food mass into the mould, tocompress the food product at least slightly in the mould and/or to cutoff the material in the mould from the food mass supply in a fillchamber.

In order to form the food product into patties, the form membercomprises at least one, preferably a plurality of moulds, which are atleast partially made of a porous material. The porous material has theadvantage, that the mould can be vented during filling of the mould toremove entrapped air and/or to supply a pressurized medium, for exampleair, to eject the formed patties out of the mould. Preferably, at leastthe bottom of the mould is made of a porous material.

The form member can be made entirely out of a porous material or theform member can comprise one or more porous inserts. These inserts cancomprise one or more moulds. Preferably, the moulds are not exchangeablebut irreversibly coupled with the plate, for example by gluing, welding,soldering and/or a friction-fit. The porous structure can be made out ofsintered material, for example stainless steel, plastic, aluminum,ceramics and/or a combination of these materials. The same is true forthe porous inserts. The mould can consist of a porous side wall and aporous bottom wall or only of a porous bottom wall. The porecross-section of the porous material is preferably designed such that itis permeable for gas, preferably air. Preferably the pore diameter isfrom 2 to 40 microns. When only using a permeable bottom wall, the othersurfaces of the mould are preferably made of an anti-stick material,like Teflon, and/or coated with such a material. Preferably, the mouldallows the forming of a 3D-shaped product; i.e. a product that does notcomprise a constant thickness over its entire extension. Thus, thebottom of the mould is preferably not flat but 3D-shaped.

The porous structure can be made for example by milling, laser drillingor spark erosion or sintering, preferably direct sintering of the porousstructure into a cavity of the plate. In that way, the pores will not beclosed or only closed to a very small degree during its manufacturing.

In order to provide a high capacity, the inventive food product formingapparatus preferably comprises multiple moulds arranged in a row. Evenmore preferably, the inventive apparatus even has multiple rows, eachrow comprising a plurality of moulds. These rows can be in a continuousprocess filled one after the other. In a discontinuous process, when forexample a reciprocating plate is used, two or more rows are preferablefilled simultaneously.

As already mentioned above, the moulds are preferably connected to theambient and/or a pressure medium supply, for example a gas and/or watersupplies. This takes preferably place via the de-aeration member. Themoulds in one row are preferably connected, for example via a channel tothe ambient and/or to the pressure medium supply. The connection can bepart of the form member itself, in the de-aeration member, in amanifold, which is connected to the form member or in the adjacentsurface between the form member and the manifold or the de-aerationmember. When using multiple rows of moulds in a form member, especiallyfor large capacities, all moulds can be connected with each other.However, a separation of the ventilation and/or pressure medium supplyper row is preferred in order to provide a homogenous supply of thepressure medium.

After the patties have been formed they have to be removed from themoulds. This is preferably done by ejecting a gas, preferably air,through the porous structure of the mould. Preferably, the ejection isan impulse. In case air is not sufficient to remove all food productsfrom the mould, preferably water or another fluid is preferably insertedmost preferably sprayed into the mould prior to its filling. In casethat the form member is a plate, this can be done during the ingoingstroke of the plate; i.e. during the movement of the plate from thedischarge to the filling position. With this fluid, a thin film will becreated on the bottom wall and/or on the side walls of the moulds, whichat least partially prevents the food product from sticking against thewall.

The product to be formed is pressed from a fill chamber into the mouldsof the form member. During this filling air entrapped in the form platemould will escape via the porous structure of the mould into theatmosphere.

An option when processing an extremely sticky food product is to blowair with low air pressure in the mould or to avoid, that the mould isvented so that a film of air is at least locally created between thefood product and the mould.

In case the formed patty is a thin product, preferably the airventilation is closed and/or a negative pressure is created between themould and the patty. This hinders the patty to fall out of the mouldduring the movement of the form member.

In case the mould comprises a porous bottom and a porous sidewall,preferably the bottom and the side wall comprise a separate ventilationand/or pressure medium supply, respectively.

According to one embodiment of the present invention the form member isa plate, which reciprocates between a filling and a discharge position.Such a forming plate is for example described in EP 0 818 148 A1. Thispatent application is hereby included by reference so that itsdescription is part of the present description.

In this patent application a forming machine is described with a springelement, for example an o-ring which presses the pressure member, here apressure plate against the form member, here a from plate and the formmember against a de-aeration member. The clearance between the pressuremember, the form member and the de-aeration member is eliminated withthe spring element and no leakage takes place. The pressure member hasaccording to another or a preferred embodiment of the present inventioncutting means such that the form product is cut when the form plate ismoving from the filling to discharge position.

In order to insure a minimum surface pressure and still adequate sealingbetween the pressure member and the form member, the pressure member ispreferably flexible, so that it equalizes roughness and/or unevenness inthe surface of the forming plate.

Even more preferably, the pressure of the pressure element can beadjusted, for example by an inflatable O-ring. This ring can be insertedinto an indentation in the surface of the pressure member. Its shape,preferably its diameter can be altered for example by pressurized airand/or pressurized water. The pressure of the pressure element ispreferably controllable even more preferably controllable by a computersystem. The pressure is preferably adjusted depending on the material ofthe form member and/or the material of the pressure plate, the wear ofthe form member and/or the pressure member and/or based on the foodproduct to be formed. The pressure plate can comprise two or morepressure elements whose pressure can preferably be altered independentlyfrom each other.

In a preferred embodiment, the apparatus comprises a base member, whosesurface preferably interacts with the pressure member. The pressureelement is preferably located between the pressure member and the basemember. More preferably, the surface adjacent to the pressure member is3D-shaped, to assure a 3D-shaped product can be removed from theinventive apparatus, especially an apparatus with a form plate.

To ensure that especially fibrous food products as whole muscle meat,spinach or the like are not withdrawn from the mould during the movementof the form member, for example during the outgoing stroke, a knifepreferably a knife with a serrated and/or waved blade in the pressuremember is provided according to an inventive or preferred embodiment ofthe present invention. In order to assure high hygiene, the knife ispreferable integrated into the pressure member itself; i.e. the pressuremember and the knife are preferably one piece of material. Preferably,the pressure member comprises an opening through which the food productis fed into the moulds. The knife is preferably provided at thecircumference of this opening. The blade of the knife is preferablyproduced by water-jet cutting. When the form member with its mould isfully charged with food product, the form member moves to its dischargeposition and passes the stationary mounted knife and the bottom side ofthe formed product and its fibers will be cut off.

According to another or a preferred embodiment of the present invention,the apparatus comprises an insertion unit to insert a stick into eachpatty. The stick is especially desirable in case, the food product is socalled finger-food. More preferably, the means is a slot.

Preferably, the insertion unit is located at the front end of the formmember, which is even more preferably a drum.

In a preferred embodiment of the present invention, the insertion unitis movable, preferably along at least a segment of a circular arc. Thus,the insertion unit can, for example, co-rotate together with a drum, sothat the drum can be operated continuously.

In another preferred embodiment of the present invention, the foodproduct forming apparatus comprises a cam that pushes the stick into thepatty, while the form member, especially the drum, is advancing. Thestick is only inserted into the cavity and/or the formed patty and thenpushed into the patty by the cam. The cam can be shaped as a ramp.Preferably, the cam is located at the front end of a drum.

Preferably, the stick is inserted into the food product during themovement of the form member from the filling to the discharge position.Another subject matter of the present invention is therefore a processfor the insertion of a stick into a patty, which are formed in a formingmember, whereas the stick is inserted while the forming member advances.

Another subject matter of the present invention is a process for theinsertion of a stick into a patty, which is formed in a forming member,whereas the stick is at least partially inserted while the formingmember advances and/or whereas the stick is moved relative to theforming member for insertion into the patty by an insertion unit.

In a preferred embodiment of the inventive process, the forming memberis a drum. Preferably, the rotation is stopped or maintained during theinsertion of the stick.

Preferably, the insertion of the stick in one row and filing of thecavity in another row takes place at least partially simultaneously.

Another preferred or inventive embodiment of the present invention is afood forming apparatus with a mould-plate that is reciprocable betweentwo positions and that comprises cavities, which are filled in thefilling station with a patty-material and which are emptied in thedischarge station and which comprises a stationary plate, whereas itfurther comprises rolling elements located between the plate and themould-plate.

The present invention relates to a food forming apparatus. In the foodforming apparatus, a patty material for example any formable, eatablematerial such as a dough, minced meat or the like, can be formed into adesired shape. This shape can be two dimensional, i.e. a disc or threedimensional, i.e. a ball. According to the present invention, the foodforming apparatus comprises a mould plate that reciprocates between twodifferent positions; i.e. a filling and a discharge position. This mouldplate comprises cavities, into which the patty material is filled,preferably pressed and thereby formed. The mould plate preferablycomprises a multitude of cavities which are arranged in an array, i.e.which comprise a multitude of parallel rows, each row preferablycomprising a multitude of cavities. The rows are preferably arrangedperpendicular to the direction of motion of the mould plate. Preferably,the cavities in one row and/or one or more rows are filledsimultaneously in the filling station. Preferably, the cavities in onerow and/or one or more rows are then emptied simultaneously in thedischarge station.

According to the present invention, the inventive food forming apparatuscomprises a plate, which is preferably part of the housing of the foodforming apparatus and thus stationary. Between this plate and at leastone surface of the mould plate, rolling elements are arranged. Theserolling elements reduce the friction of the mould plate during itsmotion between the two positions. Additionally the rolling elementsprovide a large contact area against which the mould plate can bepressed directly or indirectly. Due to the large contact area, no oronly little pressure-peak occur and/or the mould plate does not bend.

Preferably, the rolling elements are provided in a cage, in order toprevent that the rolling elements touch each other and/or have alwaysequal distance from each other.

In a preferred embodiment of the present invention, the length of therolling elements is essentially equivalent to the width of the mouldplate, i.e. the horizontal extension of the plate perpendicular to itsdirection of motion. The rolling elements are preferably cylinders morepreferably with a relatively small diameter, for example 10-30 mm,preferably 15-25 mm and even more preferably 19-21 mm. Preferably thesecylinders are arranged side by side with a relatively small distance inbetween, i.e. only sufficient space that the cylinders do not touch eachother. This preferred embodiment of the present invention assures, thatthere are no or little pressure peaks; i.e. that there is an equalpressure distribution along the mould plate, especially along the partof the mould plate where the mould cavities are located.

In another preferred embodiment of the present invention, the foodforming apparatus comprises a locking plate adjacent to the mould plateand fixed to the mould plate. Preferably the rolling elements arearranged between the stationary plate of the food forming apparatus andthe locking plate. The locking plate prevents that the material will bepressed out of the form plate and/or is utilized as a counter plate forthe rollers to avoid indentations from the rollers into the form plate.Preferably the food forming apparatus comprises a bottom plate.

In another preferred embodiment of the present invention, the foodforming apparatus comprises a seal plate between the bottom plate andthe mould plate. This seal plate seals especially the area around theinlet of the food forming material. Furthermore, the seal plate assures,that the food forming material is only distributed in the cavity but notaround the cavity. Material, that stands out of the cavity is preferablycut off by the seal plate. Thus, in a preferred embodiment, the sealplate comprises cutting means to cut off food forming material thatstands beyond the mould cavity.

Preferably, the seal plate is pressed against the mould plate withspring elements preferably adjustable spring elements. With theadjustment of the spring elements, the pressure between the seal plateand the bottom plate can be adjusted based on the food forming material.Furthermore, wear can be equalized.

Preferably, the mould plate comprises a porous mould region. In thisporous mould region, the mould plate is made of a porous material, forexample a sintered material. Through this porous material air can beejected to remove the formed patties out of the cavities. Furthermore,the passages in the porous material can be utilized to vent thecavities.

Preferably, the porous mould region is an insert into a frame of themould plate. Preferably, the insert comprises a multitude of cavities.The cavities are for example inserted into the porous mould region bymetal cutting.

In another preferred embodiment, the mould region comprises one insertper cavity.

In a yet another preferred embodiment of the present invention, the foodforming apparatus comprises one or more means to divide the airflowbetween two or more cavities or rows of cavities. This embodiment of thepresent invention is especially advantageous to avoid air-shortcuts.Preferably this means is not only present in the gap between the airinlet and the mould- and/or the locking plate but extends also at leastpartially into the porous material.

Additionally or alternatively, the means can be utilized to secure aninsert in the plate and/or as a pressure member, to assure that theinsert is tight relative to the form plate.

Another inventive or preferred embodiment of the present invention is afood forming apparatus with a mould-plate that is reciprocable betweentwo positions and that comprises cavities which are filled in thefilling station with a patty-material and which are emptied in theremoval station, whereas it comprises two discharge stations and onebelt per removal station.

The present invention relates to a food forming apparatus. In this foodforming apparatus, a patty material which is formable, for example adough, minced meat or the like, can be formed into a desired shape. Thisshape can be two dimensional, i.e. a disc or three dimensional, i.e. aball. According to the present invention, the food forming apparatuscomprises a mould plate that reciprocates between two differentpositions; i.e. a filling and a discharge position. This mould platecomprises cavities, into which the patty material is filled, preferablypressed and thereby formed. The mould plate preferably comprises amultitude of cavities which are arranged in an array, i.e. whichcomprise a multitude of parallel rows, each row preferably comprising amultitude of cavities. The rows are preferably arranged perpendicular tothe direction of motion of the mould plate. Preferably, the cavities inone row and/or one or more rows are filled simultaneously in the fillingstation. Preferably, the cavities in one row and/or one or more rows arethen emptied simultaneously in the discharge station.

According to the present invention, the inventive food forming apparatuscomprises two discharge stations, which are located to the left and theright of the filling station. The mold plate reciprocates between thesetwo stations. In these discharge stations, the formed patties areremoved from the cavity. According to the present invention, theinventive food forming apparatus comprises an individual belt perremoval station. Thus, the inventive apparatus can be operated with muchmore flexibility than the apparatus according to the state of the art.The two belts can be operated with the same or different speeds. Thetransportation direction of the two belts is preferably identical.Preferably, one belt is longer than the other and more preferably, thelonger belt is operated at a higher speed than the shorter belt.Preferably, the belts are located at least partially at differentheights. More preferably, at least one belt can comprise means to loweror lift it at least partially. In another preferred embodiment of thepresent invention at least one belt comprises different segments, whichmore preferably can be moved even more preferably rotated relative toeach other.

Preferably, at least one belt comprises means to alter the height of thebelt at least partially before and/or during the transportation of thepatties. In a preferred embodiment, the belt is tilted and/or partialsegments of a belt are lowered and lifted. This preferred embodiment ofthe present invention has the advantage, that during the removal of thepatties from the mold plate, the distance between the mold plate and thebelt can be very small, so that deformation or destruction of thepatties during their drop from the mould plate onto the belt can beavoided. During transportation along the belt however, the distancebetween the surface of the belt and the other parts of the inventivefood forming apparatus can be relatively large to avoid a collisionbetween the formed patties on the belt and other parts of the inventivefood forming apparatus.

Preferably, the two belts are connected by a seesaw. One end of thisseesaw can be brought into alignment with each of the belts. Thus, thepatty load of the two belts can be combined on one belt, which islocated downstream of the seesaw. The seesaw preferably also comprises abelt. This belt can be operated at different velocities than thevelocities of the first and/or second belt of the food forming apparatusin order to increase or decrease the distance between two patty rows.This holds also true for the transportation means downstream of theseesaw.

Preferably, at least one of the belts, the seesaw and/or the beltdownstream are shiftable sidewards, i.e. in a horizontal directionperpendicular to the direction of transportation. This preferredembodiment allows to stagger the patties on the belt.

According to a preferable or another inventive embodiment of the presentinvention, the mold plate is at least partially porous. Preferably, thecavities especially their bottom and their sidewall are made of aporous-, for example a sintered-material. This embodiment of the presentinvention has the advantage, that the patties can be ejected out of theplate for example with air. Additionally, the cavity can be vented viathe porous material during filling of the cavities.

In another preferred or inventive embodiment of the present invention,the outlet of the filling station is below the mold plate. Thisembodiment of the present invention has the advantage, that the fillingand the discharge of the mould-plate takes place on the same sides ofthe mold plate, so that there need not be any through-holes in the moldplate.

Preferably, the inventive food forming apparatus comprises two outletmeans, preferably two air outlet means to eject the patties out of themolds. This embodiment of the present invention has the advantage, thatno pistons are needed to remove the patties from the mold plate.

According to another inventive or preferred embodiment of the presentinvention, the mold plate comprises a slot to accommodate a stick. Thesticks are inserted into the patty and are utilized to hold the patty.The slot guides the stick during its insertion into the patty. The stickis preferably inserted into the patty by moving the mold plate relativeto the stick and/or the stick relative to the mold plate. The slot haspreferably a U-shaped, square or rectangular cross-section. Preferably,the slot is in connection with a cavity. This facilitates the insertionof the stick into the patty via the slot. Preferably, the slot extendsfrom the cavity in the mold plate to the side-limit of the mold platethat is oriented perpendicular to the direction of motion.

Preferably, the mold plate comprises to rows of cavities, each rowcomprising at least one, preferably a multitude of cavities, whereas thecavity/cavities in one row are staggered to the cavity/cavities in theother row. This preferred embodiment of the present invention has theadvantage that the patties can be placed on a belt in a staggeredpattern without moving the belt sidewardly.

Another subject matter of the present invention is a process for thetransportation of patties, whereas the patties are staggered. Thisembodiment of the present invention allows to increase the load on thebelt per unit-length. Furthermore it has advantages regarding thesubsequent processing and/or packaging of the patties.

Preferably, the patties comprise a stick, whereas the sticks point atleast partially in different directions. Preferably, one stick points inthe direction of motion of the transportation belt, while the next onepoints in the opposite direction.

The inventions are now explained according to FIGS. 1-32. Theseexplanations do not limit the scope of protection. The explanationsapply to all inventive embodiments of the present invention likewise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 show one embodiment of the inventive apparatus.

FIGS. 5 and 6 show the inventive pressure member.

FIGS. 7a-c show another embodiment of the inventive apparatus.

FIGS. 8a-8c show further details of the apparatus according to FIGS.1-4.

FIG. 9 shows the stick insertion.

FIGS. 10-12 show another embodiment of the apparatus with stickinsertion.

FIG. 13 shows a movable insertion unit.

FIG. 14 shows a first embodiment of the food forming apparatus.

FIG. 15 shows a second embodiment of the food forming apparatus.

FIG. 16 shows a first embodiment of the mould plate.

FIG. 17 shows a second embodiment of the mould plate.

FIGS. 18a-18e show the operation of the inventive food formingapparatus.

FIGS. 19-23 show the inventive food forming apparatus and its operation.

FIGS. 24-29 show another embodiment of the inventive food formingapparatus.

FIG. 30 shows the forming of patties with a stick.

FIG. 31 shows a belt loaded with staggered patties.

FIG. 32 shows a mold plate with staggered cavities

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 show one embodiment of the inventive forming apparatus. As canbe seen from FIGS. 1 and 2, the food product forming apparatus 3 has ahousing, which is denoted overall by 4 and comprises a base member 5,here a plate, a de-aeration member 2, here a plate, lateral guides 6between these two components (see FIG. 2) and a closure member 7 whichholds the de-aeration member 2, the base member 5 and the lateral guides6 pressed against one another. The de-aeration member 2 has ventilationholes 8. The ventilation holes 8 can be utilized to allow theventilation of the mould 11 during its filling to remove entrapped air.The ventilation holes 8 can also be used to eject a gas, for example airinto the mould 11 to create an air cushion to reduce sticking of thepatty in the mould 11. The lateral guides 6, the base member 5 and thede-aeration member 2 delimit a chamber 9, in which the form member 1 canbe displaced between a position moved inwards, which is shown incontinuous lines, and a position moved outwards, shown by broken lines.The inward position of the form member 1 is the so called fillingposition in which a mould 11 is filled with food mass. The outwardposition is the so called discharge position, in which the formed pattyis discharged from the form member 1. The base member 5 has a feedopening 10 which is connected to the feed of the food mass (notdepicted). In the moved-in position of the form member 1, the moulds 11arranged therein are in communication with the feed opening 10.According to the invention, the base member 5 is preferably providedwith a recess 12, in which a pressure member 13, here a plate issituated. The stationary pressure member 13 is shown in more details inFIGS. 5 and 6 and has an opening 14 which is aligned with the feedopening 10 in the base member 5. A groove 15 is arranged around thisopening 14, in which groove a likewise encircling spring element 16, forexample a rubber ring or an O-ring, is situated. This spring element 16is supported on the base member 5, on its region around the feed opening10. The pressure force resulting from the spring element 16 ispreferably adjustable, so that on one hand the feed opening 10 is sealedbut on the other hand the sealing force is not too high, to avoid wearof the spring element 16, the form member 1 and/or the pressure member13 and/or to improve the sealing. The adjustment of the pressure forcecan be, for example, achieved with a hollow O-ring, into which apressure fluid is filled. The pressure fluid changes the diameter of theO-ring and thus the pressure force. Preferably, the spring element 16 iscomputer-controlled. As a result, the pressure member 13 is held firmlypressed against the form member 1, so that any play of the said formmember 1 in the internal chamber 9 in the housing 4 is eliminated, inthe region of the feed opening 10. The spring element 16 also seals thegap between the pressure member 13 and the recess 12. By dint of thisresilient pressure, scarcely any leakage now takes place between thepressure member 13 and the form member 1. Moreover, this pressure member13, interacting with the form member 1, also has a cutting action, suchthat the fibers of the mass, such as meat fibers, are reliably severedwhen the form member 1 is displaced to its outwardly projectingposition. In order further to improve the seal of the pressure member 13with respect to the form member 1, preferably a further groove 17 isprovided, in which an additional spring element 18 is situated. Thepressure force of this spring element 18 is preferably also adjustableas described above.

FIGS. 3 and 4 show details of the inventive food product formingapparatus 3 according to FIGS. 1 and 2. This food product formingapparatus 3 comprises a form member 1, here a plate, which reciprocatesbetween a filling-position in which the moulds 11 in the form member 1are filled with the food product and a discharge position in which theformed food products 22, the patties, are removed from the form member1. The movement of form member 1 is depicted by the double arrow on theplate. FIGS. 3 and 4 depict the discharge position of form member 1. Theinventive food product forming apparatus 3 preferably comprises a knockout cup 19 which is connected to a piston 24. The knock out cup 19 movesfrom a start-position to a knock-out-position and back as shown by thedouble arrow on piston 24. The knock out cup 19 comprises at its bottoma perforated plate or permeable bottom 20 which is permeable for a fluidmedium, preferably gas and/or water. FIG. 3 shows the knock out cup 19in its start position. FIG. 4 shows the knock out cup 19 after it hascome into contact with the food product 22 in form member 1 and after ithas moved through the form member 1 and has knocked out the food product22 out of form member 1. After the food products 22 have been removedfrom form member 1, they fall on a transportation belt 21 and aretransported to the next processing step. The person skilled in the artunderstands, that form member 1 can comprise a multitude of moulds 11and correspondingly a multitude of knock out cups 19. The knock out cup19 can be driven individually or together in groups. The person skilledin the art furthermore understands that form member 1 can be substitutedby a intermittently or continuously rotating drum with holes in it. Inthis case, the knock out cups 19 are located preferably at the inside ofthe drum. The person skilled in the art further understands that thedepiction of the food product 22 or patties is simplified and that theycan have a 3D-shape. In the case, the bottom of the knock out cup 19,here the permeable bottom 20, needs to have a corresponding shape.

FIGS. 5 and 6 show details of the pressure member 13, which is here apressure plate. This pressure member 13 is stationary and the topsurface depicted in FIG. 5 is adjacent to the form member 1. Themovement of the form member 1 is depicted by a double arrow. Asdescribed previously, the pressure member 13 comprises an opening 14through which the food mass is fed into the moulds 11. This opening 14comprises a circumference into which at least partially, the blade 23has been worked. The blade 23 cuts the food product, for example fibersof the food product for example muscle-fibers, during the movement ofthe form member 1, especially during the outgoing movement of the formmember 1 into the discharge-position. The blade 23 is located in thepressure member 13 such, that the inner surface of the formed pattyand/or inner surface of mould 11 moves entirely across the blade 23during the movement of the form member 1. A person skilled in the artunderstands that for forming a 3D-product it can be necessary to shapethe pressure member 13 dimensionally too. In this case, the blade 23 isalso 3D-shaped. The plate is preferably worked directly into thematerial of the pressure-member, i.e. the blade 23 and the pressuremember 13 are made out of one piece. Preferably, the blade 23 isserrated and/or waved. Preferably, the blade 23 is produced bywater-jet-cutting.

FIG. 6 shows the backside of the pressure member 13 according to FIG. 5.On this side, grooves 15 and 17 have been worked into the pressuremember 13 which hold spring elements 16, 18 respectively. These springelements 16, 18 are in the present case O-rings, which are preferablyadjustable in their diameter as described above.

FIG. 7 shows another embodiment of the inventive food product formingapparatus 3. The disclosure made regarding FIGS. 1-6 also applies tothis embodiment. In this case, the form member 1 is a drum 1.2 thatrotates continuously or intermittently. The circumference of the drum1.2 comprises several moulds 11, which are located at different angularpositions and which are preferably also located in parallel, in rowsalong the axial extension of the drum 1.2. The moulds 11 comprise in thepresent case porous inserts which are embedded in the drum 1.2. Eachmould 11 is connected to a channel 25 and a branch, 28 through which theindividual mould 11 can be vented and/or through which a pressurizedmedium can be ejected in order to remove the formed food products 22 orpatties 22.1 from the moulds 11.

The inventive food product forming apparatus 3 further comprises afilling shoe which surrounds the circumference of the drum 1.2partially. It can be seen especially from FIG. 7 a, that this shoecomprises adjacent to the circumference of the drum 1.2 a pressuremember 13, which is in the present case 3D-formed in order to produce3D-shaped patties 22.1 which can be especially seen in FIG. 7 c. Betweena base member 5 and the pressure member 13, a pressure transfer means31, here lamellas 31.1, can be located, which transduce a pressure fromthe base member 5 to the pressure member 13. The pressure member 13 ismade in the present case of a flexible material so that is always incontact with the surface of the drum 1.2. The base member 5 comprisespressure means for example spring elements to press the pressure platesagainst the drum 1.2. These spring elements are preferably as alreadydiscussed above adjustable more preferred by a computer system. The drum1.2 rotates, preferably continuously, from a filling position in whichthe food product 22 is fed into the moulds 11, to a discharge position,which is depicted in FIG. 7c . In this discharge position, the formedpatties 22.1 are discharged on a transportation belt 21 and transportedaway.

FIG. 8 shows further details of the embodiment of the inventive foodproduct forming apparatus 3 according to figures FIGS. 1-4. In figureFIG. 8a , a form member 1 is depicted in its filling position. In thisfilling position, a food mass 33 is fed into the individual moulds ofthe mould plate 1.1, which are located in parallel in a row. Below themould plate 1.1 is a pressure member 13, which is in the present case3D-formed; i.e. comprises indentations in order to allow the productionof 3D-shaped products which are in the present case sticks with aregular poly-angular diameter. In order to allow ventilation of themould 11 during its filling, the mould 11, which comprises in thepresent case a porous insert, as can be seen in figure FIG. 8b , isconnected to a channel 25 and branch 28 which can be connected forexample to the ambient and allows the removal of the entrapped air. Asdepicted by the double arrow on the mould plate 1.1, the mould plate 1.1is movable from the depicted filling position into a discharge position,which can be seen in figure FIG. 8c . FIG. 8b shows details of moulds11, which are as already said, made from porous material. In the presentcase, the moulds 11 are inserts, which are inserted into a cavity 26.Each of these cavities 26 is connected to a channel 25 via a branch 28.The branch 28 and/or the channel 25 is located in a de-aeration member2. FIG. 8c shows the form member 1 in its discharge position. Here, themoulds 11 are connected via channels 25 to a pressure medium for examplepressurized air which ejects the patties 22.1 out of the moulds 11. Thechannel 25 is here part of a stationary ejector 32. It can be especiallyseen from FIG. 8c , that the surface of the form member 1, which isadjacent to the pressure member 13 is also 3D-formed, whereas theindentations of the pressure member 13 fit into convexities of the formmember 1 and vice versa.

FIG. 9 shows the insertion of a stick 29 into the food product 22 orpatties 22.1. The insertion of the stick 29 can take place during themovement of the form member 1 from the filling to the discharge positionor after the form member 1 has reached the discharge position. Theperson skilled in the art understands that the sticks 29 can bestationary and/or can be moved to utilized the insertion of the sticks29. The sticks 29 are inserted into the patties 22.1 via a slot 30.1. Bymeans of this slot 30.1 the patties 22 and the sticks 29 can be ejectedin the discharge position.

FIGS. 10-12 show another embodiment of the inventive food productforming apparatus 3, which comprises in the present case a drum 1.2,which rotates, as indicated by the arrow, counterclockwise. The drum 1.2comprises cavities 26, in which patties 22.1 can be formed. Furthermore,the inventive food product forming apparatus 3 comprises at both of itsfront ends 36 stick insertion units 34, respectively, whereas eachinserts sticks 29 into the patties 22.1. The patties 22.1 with itssticks 29 inserted are subsequently discharged on a transportation belt21 and transported away from the inventive food product formingapparatus 3. As can be especially seen from FIG. 11, each cavity 26 isconnected to an opening 30, here a slot 30.1, through which the stick 29is inserted into the patty 22.1, which is formed in the cavity 26. Inthe present case, the cavity 26 is made from a porous material.

FIG. 12 shows details of the stick insertion unit 34, which comprises inthe present case an insertion pin 35, which pushes stick 29 into thecavity 26 and thus into the formed patty 22.1. The stick insertion unit34 can be either provided stationary or moveable. In case that the stickinsertion unit 34 is stationary, the rotation of the drum 1.2 must bestopped while the stick 29 is inserted into the patty 22.1. In case thatthe insertion unit 34 is moveable, it preferably moves along a segmentof a circular arch, while it inserts the stick 29 into the cavity 26. Assoon as this is finalized, the stick insertion unit 34 moves back intoits home position and then pushes another stick 29 into the patty 22.1.In a preferred embodiment, the inventive food product forming apparatus3 comprises a multitude of rows of cavities 26 along its circumference.Preferably, while in one row the stick 29 is inserted, another row isfilled with the food forming material, at least partiallysimultaneously. This can be either done while the form member 1 ismoving or while it is stationary.

In FIG. 13, a moveable stick insertion unit 34 is depicted. In figureFIG. 13a the stick insertion unit 34 is shown in its home position. Theform member 1, in the present case a drum 1.2, comprises a multitude ofrows with at least one cavity. The drum 1.2 rotates counter clockwise.As soon as row 1 has reached the stick insertion unit 34, theyco-rotate. During this co-rotation (please compare FIGS. 13b and 13c )the stick 29 is inserted into the cavity 26 and thus into the patty22.1. As soon as this is finalized (please compare FIG. 13c ), the stickinsertion unit 34 rotates clockwise (please compare FIG. 13 d) into itshome position and then starts co-rotating with row 2 in order to inserta stick 29 into the cavity of this row. Preferably, the rotation intothe home position is faster than the co-rotation during the insertion ofthe stick 29.

FIG. 14 shows a first embodiment of an inventive food forming apparatus.This food forming apparatus comprises a top plate 12.1 and a bottomplate 11.3, which are stationary parts of the inventive apparatus, i.e.its frame. These plates 11.3, 12.1 confine a gap in which a mould plate17.1 is located. The mould plate 17.1 reciprocates between a fillingposition and a discharge position. The mould plate 17.1 comprises aframe 2.1 which is preferably made from a solid material. Furthermore,the mould plate 17.1 comprises a porous mould region 7.1, which is madefrom a porous material for example from a sintered material. In thisporous mould region 7.1, cavities 5.3 have been machine-cut. The porousmould region 7.1 preferably comprises an array of cavities 5.3, i.e. thecavities 5.3 arranged in several rows whereas each row comprises amultitude of cavities 5.3. Each row extends preferably perpendicular tothe direction of motion. The cavities 6.3 of the each rows arepreferably emptied and filled simultaneously. The cavities 5.3 of two ormore rows can also be emptied and filled simultaneously. Adjacent to thetop surface of a mould plate 17.1 the inventive food product formingapparatus 3 comprises a locking plate 9.1. The locking plate 9.1protects the mould plate 17.1 from above, for example againstindentations from the rollers. Between the locking plate 9.1 and the topplate 12.1 a multitude of rolling elements 10.1 are arranged. Theserolling elements 10.1 extend preferably over the entire width W (pleasecompare FIG. 16) of the mould plate 17.1. In the present case, therolling elements 10.1 are cylinders with a small diameter, app. 20 mm.These cylinders are arranged side by side with a very small distance inbetween. In the present case, the pitch is 25 mm, so that the distancebetween the rollers is 5 mm. This preferred embodiment of the presentinvention assures an equal pressure distribution in the mould plate 17.1and no or little bending of the mould plate 17.1. The rolling elements10.1 assure, that there is little friction between the mould plate 17.1and the frame 2.1 of the food forming apparatus, i.e. the stationary topplate 12.1 during its motion between the two positions. Furthermore, theinventive patty machine comprises an inlet 13.1, through which the pattymaterial is inserted preferably pumped into the cavities 5.3. This inletis located in a filling station 6.1 which itself is located in thefilling position 3.1.

Furthermore, the inventive food forming machine comprises a dischargeposition 4.1, in which the formed patties 22.1 are discharged from themould plate 17.1 for example onto a belt 27.1. In the present casepressurized air, which is forced through the porous material, is used toeject the formed patties 22.1. The food forming apparatus thereforecomprises in its discharge position 4.1 a discharge station 8.1, in thepresent case, means to force air through the porous region, especiallythrough the cavities 5.3 more specifically through the bottom andthrough the sidewalls of the cavity 5.3.

FIG. 15 shows a second embodiment of an inventive food forming machine.In comparison to the food forming machine according to figure FIG. 14,the present food forming machine additionally comprises a seal plate15.1, which is located between the bottom plate 11.3 and the bottomsurface of the mould plate 17.1. The seal plate 16.1 is pressed againstthe mould plate 17.1 by spring elements 16, preferably adjustable springelements 16. This pressure force also presses the mould plate 17.1against the locking plate 9.1 and the locking plate 9.1 against therolling elements 10.1. The seal plate 15.1 seals the area around theinlet and assures that essentially all the food forming material isinserted into the cavities 26 and not around the cavities 26.Furthermore, the seal plate 15.1 cuts off material that stands beyondthe cavities 26 of the mould plate.

FIG. 16 shows a first embodiment of the mould plate 17.1. In the presentcase, the porous mould region 7.1 is made from one piece, which isinserted for example pressed, screwed, welded, soldered or glued intothe frame 2.1. The porous mould region 7.1 comprises at its lowersurface a multitude of cavities, arranged in an array of a multitude ofrows, each row comprising a multitude of cavities 5. In order to assure,that there is no air-shortcut regarding the air which is pressed intothe porous insert to eject the patties, the inventive food formingmachine comprises diverters 18.2 (in the present case four diverters),which are located in the gap between the locking plate 9.1 and the mouldplate 2.2 and which also extend into the surface of the porous mouldregion 7.1.

FIG. 17 shows another embodiment of the mould plate. In the presentcase, the porous elements are discrete elements, which are inserted intoholes in the mould plate. One cavity comprises one individual porouselement. Other than that, it is referred to the explanations accordingto FIG. 16.

FIG. 18 shows the operation of the inventive food forming apparatus. InFIG. 18a , the cavities 5.3 are in the discharge position 4.1. In thisdischarge position 4.1, air is forced via an inlet into the cavities5.3, especially into the porous mould region 7.1. The air flows throughthe porous mould region 7.1 into the cavities 5.3 and ejects the pattiesas depicted by arrow 20.1. The formed patties 22.1 preferably fall on atransportation belt 21 and are transported their way. As soon as thepatties 22.1 have been discharged from the mould plate, the mould platemoves to the left as depicted by arrow 20.4 in FIG. 18b . During theingoing stroke and after the mould plate has reached its filing position3.1 (FIG. 18c ), food forming material is inserted into the cavities5.3, preferably pressed into the cavities of the mould plate 17.1, whichis depicted by arrow 20.5. The porous material can be used during thisstep to remove entrapped air from the cavities.

As depicted in FIG. 18d , the mould plate is moved back to its dischargeposition 4.1, as soon as the filling of the cavities is completed, andthen again air is forced through ejection medium supply 8.1, to removethe formed patties 22.1 out of the mould plate as can be seen in FIG. 18e.

FIG. 19 shows the inventive food forming apparatus, which comprises amold plate 2.2 with a multitude of cavities 5.3. In the present example,the mold plate 2.2 comprises four rows of cavities 5.3, whereas each rowcomprises a multitude of cavities 5.3. The rows are orientedperpendicular to the motion of the mold plate 2.2. The motion of themold plate 2.2 is depicted by the double arrow. Furthermore, theinventive food forming apparatus comprises one filling station 6.1 inwhich the patty material is pressed into one or more rows of cavities5.3 simultaneously. In the present example, two rows of cavities 5.3 arefilled simultaneously. Furthermore, the inventive food forming apparatuscomprises a first discharge station 8.2 and a second discharge station7.2. In the embodiment according to FIG. 19 two rows of cavities arepresently emptied 5.1 in the second discharge station 7.2, whilesimultaneously two rows of cavities are filled 5.2 with the food formingmaterial in the filling station 6.1. As can be seen from FIG. 19, eachdischarge station 7.2, 8.2 comprises its own belt 9.2, 10.3, whereas thefirst discharge station 8.2 is adjacent to belt 10.2 and the seconddischarge station 7.2 is adjacent to belt 9.2. In FIG. 19 the formedpatties are presently loaded on belt 9.2 and transported in a directiondepicted by the arrow. Belt 9.2 preferably comprises three segments9′-9′″ whereas segments 9′ and 9″ are movable relative to segment 9′,preferably the belt 9.2 comprises two axis 18.3, 19.3, whereas segment9″ can turn around axis 18.3 relative to segment 9′″ and segment 9′ canturn relative to segment 9″ around axis 19.3. Furthermore, belt 9.2comprises means 11.4, for example motor means, which can lower and liftbelt 9.2 especially its segments 9′, 9″.

FIG. 20 shows the situation after the patties (not depicted) have beendropped on segment 9′ of belt 9.2. Afterwards, this belt is lowered toavoid a collision of the patties especially with the means of thefilling station 6.1. The patties are transported from the left to theright as depicted by the arrow. Simultaneously or sequentially, moldplate 2.2 is moved into its second position (please compare FIG. 20) inwhich the cavities which have just been emptied are now filled withpatty material in the filling station. The cavities which have beenfilled in the previous step have now been aligned with the seconddischarge station 7.2. In this discharge station 7.2 air is ejected inorder to eject the formed patties (not depicted) on belt 10.3.Subsequently, as can be seen in FIG. 22 belt 10.3 is tilted and therebylowered in order to avoid a collision between the patties on the beltand the food forming apparatus. Afterwards as can be seen from FIG. 23the mold plate 9 is moved back into the position as already depicted inFIG. 19 and the process restarts.

As can be seen from FIG. 19-23, the outlet of the filling station 13.2,which is in the present case designed as a plate, has a width so thatfour rows of cavities can be filled simultaneously. Additionally, theoutlet comprises a divider 17.2, for example a valve, that assures, thatthe patty material is only ejected through the segment of outlet platethat is covered by the mold-plate.

FIGS. 24-29 show a second embodiment of the present invention, which isessentially identical to the embodiment according to FIGS. 19-23 so thatthe disclosure regarding figures FIGS. 19-23 also applies to thisembodiment. In this embodiment, the belt 9.2 is made from one segmentand is tilted in order to increase the space between the belt 9.2 andthe filling station 6.1 especially the distance between segment 9′ andfilling the filling station 16.2. Additionally, this embodiment of thepresent invention comprises a seesaw 12.3, which can be aligned eitherwith belt 9.2 or with belt 10.3. In FIG. 24 the patties are loaded onbelt 9.2. Thus, the seesaw 12.3 is aligned with this belt 9.2. Then, ascan be seen in FIG. 26, the mold plate 2.2 is moved into its secondposition in which the mold cavities are emptied on belt 10.3. Duringthis movement or afterwards, the seesaw 12.3 is tilted so that it isaligned with belt 10.3, as can be seen in FIG. 27. Then, as depicted inFIGS. 28 and 29, the mold plate 2.2 is moved back into its initialposition (please compare FIG. 24) and the seesaw is again aligned withbelt 9.2. Due to the seesaw, the loads of the belts 9.2 and 10.3 can becombined on one belt. The seesaw 12.3 or a belt that is downstream ofthe seesaw can be operated at a different speed than the seesaw itselfor belts 9.2 and 10.3 in order to increase or decrease the distancebetween two rows.

FIG. 30 shows yet another embodiment of the present invention. In thepresent case, sticks 21.3 are inserted into the patties 25.1 afterand/or while the patties 25.1 are formed. The mold plates 2.2 thereforecomprise one slot 20.3 per cavity, which guides the stick 21.3 duringits insertion into the patty 25.1. The stick 21.3 can be inserted intothe patty 25.1 by moving the stick 21.3 and/or by moving the mold plate2.2. The slots 20.3 are open towards the bottom and extend from thecavity towards the side limit 23.1 of the mold plate 2.2 that isperpendicular to the motion of the mold plate 2.2 which is depicted bythe double arrow. Due to the opening of the slot 20.3 towards thebottom, the patty 25.1 plus the stick 21.3 can be easily deformed fromthe cavity of the mold plate 2.2. Due to the direction of the slot 20.3in the mold plate 2.2, patties 25.1 are formed whose stick 21.3 pointsin the direction of the motion of the belt (patties on belt 10.3) andwhose stick 21.3 is directed opposite of the motion of the belt (pattieson transportation belt 9.2).

By means of for example a seesaw 12.3 as depicted in FIGS. 24-29, apattern as depicted in FIG. 31 can be created. The person skilled in theart understands that this pattern also requires that belt 9.2, belt10.3, the sea saw 12.3 and/or belt 24.1 downstream of belt 9.2 and 10.3and/or the seesaw 12.3 have to be movable sideward, i.e. horizontallyand perpendicularly to the direction of motion of the belt and/or amotion with such a component. The pattern according to FIG. 31 has theadvantage, that the patty load per unit area of a belt can be increasedwhich is advantageous for further processing of the patties and/or thepackaging of the patties because a relatively smaller package is needed.The person skilled in the art understands, that this is also true forpatties without a stick.

Staggered patties as depicted in FIG. 31 can also be achieved byarranging the cavities in the mold plate 2.2 in a staggered mode, asdepicted in FIG. 32. With such a mold plate, the sideward motion of oneof the belts and/or the seesaw is not needed.

LIST OF REFERENCE SIGNS

-   -   1 form member, 1.1 mould plate, 1.2 drum, food forming apparatus    -   2 de-aeration member, 2.1 frame, 2.2 mould plate    -   3 food product forming apparatus, 3.1 filling position    -   4 housing, 4.1 discharge position    -   6 base member, 5.3 cavities    -   5.1 cavities being emptied    -   5.2 cavities being filled    -   6 lateral guides, 6.1 filling station    -   7 closure member, 7.1 porous mould region, 7.2 second discharge        station    -   8 ventilation holes, 8.1 ejection medium supply, 8.2 first        discharge station    -   9 chamber, 9.1 locking plate, 9.2 belt    -   9′-9′″ segments of the belt    -   10 feed opening, 10.1 rolling element, zylinder, 10.3 belt    -   11 mould, insert, plate, 11.3 bottom plate, 11.4 means    -   12 recess, 12.1 top plate, top plate, 12.3 seesaw    -   13 pressure member, inlet, 13.2 outlet of the filling station    -   14 opening, outlet, first outlet means    -   15 groove, 15.1 seal plate, second outlet means    -   16 spring element, spring element, 16.2 filling of the filling        station    -   17 groove, 17.1 mould plate, 17.2 divider    -   18 spring element, 18.2 divider, 18.3 axis    -   19 knock out cup, ejection medium, air, 19.3 axis    -   20 permeable bottom, 20.1 arrow, dropping patty, 20.3 slot, 20.4        arrow, 20.5    -   arrow    -   21 transportation belt, patty-material supply, 21.3 stick    -   22 food product, 22.1 patty, 22.2 row of cavity    -   23 blade, 23.1 side limit    -   24 piston, belt    -   25 channel, 25.1 patty    -   26 cavity, roller cage, gas, air    -   27 indentation, 27.1 belt, vent    -   28 branch, patty transport    -   29 stick    -   30 opening, 30.1 slot    -   31 pressure transfer means, 31.1 lamellas    -   32 ejector    -   33 food mass    -   34 stick insertion unit    -   35 insertion pin    -   36 front end    -   W width of the mould plate    -   L region, in which the cavities are arranged, porous mould        region

1. A food product forming apparatus to produce patties, the food productforming apparatus comprises: a form member; a plurality of mouldsarranged on the form member in which the patties are formed; a pressuremember; and a means to insert a stick into a patty, wherein the formmember is located adjacent to a pressure member, wherein the form memberis at least partially made from a porous material, and wherein thepressure member is 3D shaped. 2.-8. (canceled)
 9. The food productforming apparatus according to claim 1, wherein the means is a slot.10.-14. (canceled)
 15. The food product forming apparatus according toclaim 1, wherein the food forming apparatus comprises a stick insertionunit.
 16. The food product forming apparatus according to claim 15,wherein the stick insertion unit is located at a front end of the formmember.
 17. The food product forming apparatus according to claim 15,wherein the stick insertion unit is movable.
 18. The food productforming apparatus according to claim 15, wherein the food productforming a apparatus comprises a cam that pushes the stick into the pattywhile the form member is advancing. 19.-41. (canceled)
 42. A process ofinserting a stick into a patty, which is formed in the food productforming apparatus of claim 1, wherein the process includes a step ofinserting the stick at least partially into the patty while the formmember advances and/or the stick is moved for insertion into the pattyby an insertion unit.
 43. The process according to claim 42, wherein theform member is a drum, and during the inserting step, rotation of thedrum is stopped or maintained.
 44. The process according to claim 43,wherein insertion of the stick in one row of cavities and filling ofcavities in another row takes place at least partially simultaneously.45. The process according to claim 42, wherein the patties arestaggered.
 46. The process according to claim 45, wherein the stickspoint at least partially in different directions.
 47. The food productforming apparatus according to claim 9, wherein the slot extends from acavity in a mold plate to a side-limit of the mold plate that isoriented perpendicular to a direction of motion of the form member. 48.The food product forming apparatus according to claim 9, wherein eachcavity is connected to a corresponding slot through which the stick isinserted into the patty.
 49. The food product forming apparatusaccording to claim 15, wherein the stick insertion unit is stationary,and rotation of the form member is stopped while the stick is insertedinto the patty.
 50. The process according to claim 43, wherein insertionof the stick takes place during movement of the form member from afilling position to a discharge position, or takes place after the formmember has reached the discharge position.
 51. The food product formingapparatus according to claim 15, wherein the stick insertion unitcomprises an insertion pin that is adapted to push the stick into thepatty.
 52. The food product forming apparatus according to claim 15,wherein the stick insertion unit is moveable along at least a segment ofa circular arc while inserting the stick into a cavity, and whereinafter the stick is inserted into the cavity, the stick insertion unitmoves back to a home position where the stick insertion unit beginsinserting insert a subsequent stick into a subsequent cavity.